What are the differences between hot-dip galvanized wire and electro-galvanized wire?

Hot-dip galvanized wire and electro-galvanized wire are two common galvanizing processes, with significant differences in their technological procedures, zinc coating characteristics, and subsequent applications. Below is an introduction to the main differences between the two and an analysis of their usage rates, provided by galvanized wire manufacturers:

Process Differences

Hot-dip Galvanized Wire

Steel wire is immersed in molten zinc, forming a metallurgical bond between the zinc coating and the wire surface. The zinc coating is relatively thick, typically 30-200 microns or even thicker, with a rough surface but strong adhesion and excellent corrosion resistance.

Electro-galvanized Wire

A layer of zinc is deposited on the steel wire surface through electrolysis. The zinc coating is thin, usually 5-30 microns, with a smooth and uniform surface but weak adhesion and relatively poor corrosion resistance.

Performance Differences

Corrosion Resistance

Hot-dip galvanized wire has a thicker zinc coating and stronger corrosion resistance, making it suitable for outdoor or harsh environments; electro-galvanized wire has a thin zinc coating and is suitable for indoor or mildly corrosive environments.

Mechanical Properties

The high temperature involved in the hot-dip galvanizing process may have a certain impact on the mechanical properties (e.g., toughness) of the steel wire; electro-galvanizing has little effect on the mechanical properties of the steel wire.

Appearance

Electro-galvanized wire has a smoother and more uniform surface, suitable for scenarios with high aesthetic requirements; hot-dip galvanized wire has a rough surface but is more durable.

Usage Rate in Subsequent Applications

Hot-dip Galvanized Wire

It has a high usage rate in fields such as outdoor engineering, building fences, agricultural breeding, and highway guardrails, due to its strong corrosion resistance and suitability for long-term exposure to humid, rainy, or corrosive environments.

Electro-galvanized Wire

It is mostly used in indoor environments or scenarios with high requirements for surface smoothness, such as home decoration, electronic products, and light-duty mesh sheets.

Hot-dip galvanized wire has a higher usage rate, especially in outdoor and industrial fields, thanks to its superior durability and corrosion resistance. Electro-galvanized wire is suitable for scenarios with high requirements for surface smoothness and precision but has a relatively low usage rate, mainly applied in light industry or indoor settings. If long-term durability and corrosion resistance are pursued, hot-dip galvanized wire is the better choice; if appearance and cost are prioritized, electro-galvanized wire is more suitable.